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ELECTRICCHAIN HOISTER and NER

SERIES1/8 Ton through 20 Ton Capacity

EDOC0202REV. 0

EFFECTIVE: September 23, 2002

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This equipment should not be installed, operated ormaintained by any person who has not read and understoodall the contents of this manual. Failure to read and complywith the contents of this manual can result in serious bodilyinjury or death, and/or property damage.

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Table of Contents

Section Page Number

1.0 Important Information and Warnings …………………………………………………………. . . .4

1.1 Terms and Summary

1.2 Warning Tags and Labels

2.0 ER and NER Repair Manual Information. .………………………………………….…………. . 8

2.1 Purpose

2.2 Difference Between the ER and NER

2.3 Design Concept

2.4 Tools Required

2.5 Instructional Sequence

3.0 Hoist Disassembly Procedure ………………………………………………………. . . . . . . . . 11

3.1 Outer Part Removal

3.2 Disassembly, Controls Unit

3.3 Disassembly, Gear Case and Gear Parts

3.4 Disassembly, Chain Guide and Load Chain

3.5 Disassembly, Motor

3.6 Disassembly, Body

3.7 Disassembly, Motor Brake

4.0 Hoist Reassembly Procedure ………………………………………………………. . . . . . . . . 27

4.1 Reassembly, Motor Brake

4.2 Reassembly, Partial Chain Guide

4.3 Reassembly, Body

4.4 Reassembly, Motor

4.5 Reassembly, Load Chain

4.6 Reassembly, Gear Case and Gear Parts

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Table of Contents

Section Page Number

4.0 Hoist Reassembly Procedure, Continued …………………………………………. . . . . . . . . 27

4.7 Reassembly, Controls Unit

4.8 Checking Hoist Operation

5.0 Electrical Troubleshooting . . . .………………………………………………………. . . . . . . . . 42

5.1 Principle of Operation

5.2 Design Concept

5.3 Count/Hour Meter (C/H)

5.4 Additional Tools Required

5.5 Troubleshooting/Repair

Appendix A – Inspection Methods, Criteria and Wear Measurements

Appendix B – Inspection Methods, Criteria and Wear Measurements for Large Capacity (N)ER

Appendix C – Electrical Troubleshooting Guide and Wiring Diagrams

Appendix D – Harrington Hoists, Inc. Contact Information

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1.0 Important Information and Warnings

1.1 Terms and SummaryThis manual provides important information for personnel involved with the repair of this product. Althoughyou may be familiar with this or similar equipment, it is strongly recommended that you read this manual beforerepairing or operating the product.

Danger, Warning, Caution and NoticeThroughout this manual there are steps and procedures that can present hazardous situations. The followingsignal words are used to identify the degree or level of hazard seriousness.

������ Danger indicates an imminently hazardous situation which, if not avoided, will result indeath or serious injury, and property damage.

������� Warning indicates an imminently hazardous situation which, if not avoided, could result indeath or serious injury, and property damage.

����� Caution indicates a potentially hazardous situation which, if not avoided, may result minoror moderate injury or property damage.

����� Notice is used to notify people of installation, operation, or maintenance information whichis important but not directly hazard-related.

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These general instructions deal with the normal repair, operation, and maintenance situations encountered with theequipment described herein. The instructions should not be interpreted to anticipate every possible contingency or toanticipate the final system, crane, or configuration that uses this equipment. For systems using the equipmentcovered by this manual, the supplier and owner of the system are responsible for the system’s compliance with allapplicable industry standards, and with all applicable federal, state and local regulations/codes.

This manual includes instructions and parts information for a variety of hoist types. Therefore, all instructions andparts information may not apply to any one type or size of specific hoist. Disregard those portions of the instructionsthat do not apply.

Use only Harrington authorized replacement parts in the service and maintenance of this hoist.

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Equipment described herein is not designed for and MUST NOT be used for lifting, supporting, or transportingpeople, or for lifting or supporting loads over people.

Equipment described herein should not be used in conjunction with other equipment unless necessary and/orrequired safety devices applicable to the system, crane, or application are installed by the system designer, systemmanufacturer, crane manufacturer, installer, or user.

Modifications to upgrade, rerate, or otherwise alter this equipment shall be authorized only by the original equipmentmanufacturer.

Equipment described herein may be used in the design and manufacture of cranes or monorails. Additionalequipment or devices may be required for the crane and monorail to comply with applicable crane design andsafety standards. The crane designer, crane manufacturer, or user is responsible to furnish these additional itemsfor compliance. Refer to ANSI/ASME B30.17, “Safety Standard for Top-Running Single Girder Cranes”;ANSI/ASME B30.2 “Safety Standard for Top-Running Double-Girder Cranes”; and ANSI/ASME B30.11 “SafetyStandard for Underhung Cranes and Monorails”.

If a below-the-hook lifting device or sling is used with a hoist, refer to ANSI/ASME B30.9, “Safety Standard forSlings” or ANSI/ASME B30.20, “Safety Standard for Below-the-Hook Lifting Devices”.

Hoists and cranes, used to handle hot molten material may require additional equipment or devices. Refer to ANSIZ241.2, “Safety Requirements for Melting and Pouring of Metals in the Metalcasting Industry”.

Electrical equipment described herein is designed and built in compliance with Harrington's interpretation ofANSI/NFPA 70, “National Electrical Code”. The system designer, system manufacturer, crane designer, cranemanufacturer, installer, or user is responsible to assure that the installation and associated wiring of these electricalcomponents is in compliance with ANSI/NFPA 70, and all applicable Federal, State and Local Codes.

Failure to read and comply with any one of the limitations noted herein can result in serious bodily injury or death,and/or property damage.

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HAZARDOUS VOLTAGES ARE PRESENT IN THE CONTROL BOX, OTHER ELECTRICAL COMPONENTS,AND CONNECTIONS BETWEEN THESE COMPONENTS.

Before performing ANY mechanical or electrical maintenance on the equipment, de-energize (disconnect) the mainswitch supplying power to the equipment; and lock and tag the main switch in the de-energized position. Refer toANSI Z244.1, “Personnel Protection – Lockout/Tagout of Energy Sources”.

Only trained and competent personnel should inspect and repair this equipment.

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It is the responsibility of the owner/user to install, inspect, test, maintain, and operate a hoist in accordance withANSI/ASME B30.16, “Safety Standard for Overhead Hoists”, OSHA Regulations and ANSI/NFPA 70, NationalElectric Code. If the hoist is installed as part of a total lifting system, such as an overhead crane or monorail, it isalso the responsibility of the owner/user to comply with the applicable ANSI/ASME B30 volume that addresses thattype of equipment.

It is the responsibility of the owner/user to have all personnel that will install, inspect, test, maintain, and operate ahoist read the contents of this manual and applicable portions of ANSI/ASME B30.16, “Safety Standard forOverhead Hoists”, OSHA Regulations and ANSI/NFPA 70, “National Electric Code”. If the hoist is installed as partof a total lifting system, such as an overhead crane, the applicable ANSI/ASME B30 volume that addresses thattype of equipment must also be read by all personnel.

If the hoist owner/user requires additional information, or if any information in the manual is not clear, contactHarrington or the distributor of the hoist. Do not install, inspect, test, maintain, or operate this hoist unless thisinformation is fully understood.

A regular schedule of inspection of the hoist in accordance with the requirements of ANSI/ASME B30.16 should beestablished and records maintained.

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1.2 Warning Tags and LabelsThe warning tag illustrated below in Figure 1-1 is supplied with each hoist shipped from the factory. Ifthe tag is not attached to your hoist’s pendant cord, order a tag from your dealer and install it. Readand obey all warnings attached to this hoist. Tag is not shown actual size.

front back

Figure 1-1 Warning Tag Attached to Hoist

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2.0 ER and NER Repair Manual Information

2.1 PurposeThe purpose of this manual is to provide disassembly and assembly instructions for the ER/NER family of hoists1/8 through 20 Ton. It is also intended to act as a diagnostic guide for troubleshooting various hoist problemsand provide applicable solutions. Instructions provided are generic and intended to apply to all sizes of hoistscovered by this document.

2.2 Difference between the ER and NERThe NER has a friction clutch mechanism that provides over winding protection. The ER has amechanical load brake/friction clutch combination and an electronic count/hour meter in the control circuit.The ER has a vented oil plug where as the NER has a solid vent plug. Finally, a brake label is placed onthe ER.

2.3 Design ConceptThe ER/NER hoist is a modular design consisting of four primary parts.

1. Controls Section- This section houses the electrical components such as the transformer, limitswitch(s) and motor contactors.

2. Gear Case - This section consists of the gear system. A mechanical brake with friction clutch (ERonly).

3. Body - This section consists of the chain guide, load chain, load sheave and suspension hooks.

4. Motor and Fan Cover - This section consists of the motor frame with stator, motor shaft with rotor,pull rotor, rotor, thrust disc, motor brake spring, brake drum, and fan.

This concept allows any ER/NER model to be disassembled and repaired according to specific requirements ofthe repair job. For a complete list of parts and an exploded view- see the ER/NER owners manuals.

2.4 Tools Required

• ¼” and 3/8” drive metric socket sets

• metric Allen wrenches

• metric Hex bit sockets

• #1, 2, & 3 Philips screwdrivers

• Medium and Large Flat blade screwdrivers

• Needle nose pliers

• Small snap ring pliers internal/external

• 6” adjustable wrench

• Feeler Gages (0.010-0.080” range)

• Sm. Plastic or Rubber Mallet

• Small 2 arm wheel/pulley remover

• Bearing puller

• Electrical tape

• Safety glasses

• Vise or 2 clamps

• Ball bearing and oil seal drivers (to installseals/bearings)

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2.5 Instructional Sequence

3.0 Hoist Disassembly3.1 Removal of outer parts.

3.2 Disassembly, Controls unit.

3.3 Disassembly, Gear Case and Gear Parts.

3.4 Disassembly, Chain Guide and Load Chain.

3.5 Disassembly, Motor.

3.6 Disassembly, Body.

3.7 Disassembly, Motor Brake.

4.0 Hoist Reassembly4.1 Reassembly, Motor Brake

4.2 Reassembly, Partial Chain Guide.

4.3 Reassembly, Body.

4.4 Reassembly, Motor.

4.5 Reassembly, Load Chain.

4.6 Reassembly, Gear Case and Gear Parts.

4.7 Reassembly, Controls Unit.

4.8 Checking Operation.

5.0 Electrical TroubleshootingAppendix A- Inspection Methods, Criteria, and WearMeasurements.

Appendix B- Inspection Methods, Criteria, and WearMeasurements for Large Capacity.

Appendix C- Electrical Criteria and Wiring Diagram

Appendix D- Harrington Hoists, Inc. ContactInformation

Figure 1 - Hoist Sections

������ Improper disassembly/assembly may cause a serious accident. Disassembly/ assembly should beconducted by a qualified and well-experienced service technician, otherwise please contact a Harrington AuthorizedRepair Center. (You can contact Harrington for a list of official repair centers. See Appendix D to this manual to find arepair center nearest you.)

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• Perform disassembly and assembly procedures in accordance with this manual.• Never connect additional links to the load chain.• Remove dirt and contamination from disassembled parts such as gears.• When reassembling the hoist, the following parts must be replaced with new:

- GEAR OIL - PACKING - OIL SEALS

- SNAP RINGS - SPLIT PINS - O-RINGS

• Use thread-locking adhesive when re-installing bolts where indicated.• Always use Harrington genuine parts for replacement.

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3.0 Hoist Disassembly

3.1 Outer Part Removal

������ Hazardous voltages are presentin the control box, other electrical components, andconnections between these components.Only trained and competent personnel should inspectand repair this equipment.A) De-energize (disconnect) the main switchsupplying power to the equipment, and lock and tagthe main switch in the de-energized position.B) Remove plug 4P (4 pin Connector) of the powersupply cable complete set.

����� The 4P and 5P plugs are quickdisconnects; therefore, just loosen the threadednut on the connector and pull connector from hoist.

C) Remove the cable support wire from the bodyby removing the machine screw attaching thecable support to the hoist.

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D) Remove plug 5P (5 pin connector) of the pushbutton cable assembly.

E) When the hoist is used without a chain container,the free end of the chain is attached to the hoist bodyas shown in Figure to the right. Remove the no loadend of the chain from Chain Guide A by detaching theEnd Wire or End Suspender installed on the hoist.For 5 ton hoist, remove the no load end of the chaindirectly from Chain Guide A if Chain Guide A isnotched to accept the chain.

F) If a chain container is installed, remove the chaincontainer from the body.

G) Drain the gear oil by removing the oil plug and plugpacking from the bottom of the gear case.

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3.2 Disassembly of the Controls Unit

����� Never disassemble the electricchain hoist while it is suspended. Only performdisassembly and assembly repair work while the hoistis supported on a stable and level work surface.

A) PLACE HOIST ON WORKBENCH SO THATTHE CONTROLS SECTION IS ON TOP.

B) Loosen and remove socket bolts and open thecontroller cover. If necessary, loosen the cover bytapping it lightly with a plastic or rubber mallet.

����� Although the controller covercan be suspended, the cover may fall off of thehoist if there is a loose suspension hook.

C) Detach the cover suspender C from suspenderby unscrewing the two retaining hooks.

D) Remove lead-wires of the motor from terminalplate.

E) Loosen and remove plate screws and to enableplate to swing out on hinge.

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F) On the under side of the controls plate, removelead-wires of the motor from the terminal strip. Forconvenience, group wires removed from eachterminal together and mark with the terminal stripidentification to prevent misconnecting wiringduring reassembly. Several models will havewiring passing through to the front side of theplate. Disconnect and mark these wires, too.

G) Make sure all motor leads are clear of the plateand tape the wires together so that they passthrough the body sections without chaffing orscraping the wires.

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3.3 Disassembly of the Gear Case and Gear Parts

A) Swing the electrical controls plate open,remove the two screws retaining plate A.

B) Using pliers, pull out the connection shaftand the fixing shaft to disconnect the top hookassembly or connection yoke from the hoist.

����� Once the Shafts areremoved the hook and yokes will fall from thehoist.

C) For the ER - Remove the socket bolts andtap the controls case lightly with a plastic orrubber mallet to remove the body section.

����� Take precautions toprevent damage to the gasket during removalof the controls section. If damaged, the gasketmust be replaced with a new gasket duringreassembly. Also, lift off the controls sectioncarefully to prevent damaging motor wiring.

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D) For NER, remove the friction plug, oil sealand nut cover from the gear case. (Do notremove oil seal, unless it is to be replaced.)Remove the socket bolts connecting the gearcase to the body. Tap the controls sectionlightly with a plastic or rubber mallet to releaseit from the body section.

����� Take precautions toprevent damage to the gasket duringremoval of the controls section. Ifdamaged, the gasket must be replacedwith a new gasket during reassembly.Also, lift off the controls section carefullyto prevent damaging motor wiring.

E)� For ER -Lift out the complete friction

clutch set

� For NER -Remove the wavy washer,then pull out the complete friction clutchset.

F) Pull out the load gear bearing from the gearcase using a bearing remover.

G) Remove the snap ring to pull out the loadgear.

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H) For three gear hoists, remove the ballbearing, needle bearing and gear B assemblywith bearing. Remove socket bolt and springwasher from gear plate and remove gear plate.

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FOR ER ONLY – MECHANICAL BRAKE WITH FRICTION CLUTCH DISASSEMBLY

I) Remove the thrust disc and the thrust collar fromthe mechanical brake with friction clutch completeset. To pull out the friction clutch assembly rotateit.

����� Thrust disc can be removedwith needle nose pliers.

J) Remove the ratchet, the brake collar, and thegear by rotating the assembly.

������ Do not attempt to adjust thefriction clutch assembly or mechanical frictionassembly. If you think an adjustment is needed,contact Harrington.

K) Remove the snap ring from the body andremove the pawl and the pawl spring.

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3.4 Disassembly of the Chain Guide and Load Chain

A) Remove the stopper, and the cushion rubber orthe chain spring from the no load side of the loadchain.

B) Pull out the load chain from the body. Pulling thechain out of the body from the load side.

C) If hoist is equipped with upper limit or an upper/lower limit switch remove the split pin and pull out thelimit lever pin from the lever coupling.D) Remove the limit lever pin, the lever coupling, andthe limit lever collar from the limit lever S (an upperlimit switch type) or the limit lever assembly (an upper/lower limit switch type).

E) Remove the limit lever S (an upper limit switchtype) or the limit lever assembly (an upper/ lower limittype) from the chain guide A (AL).

F) Remove the socket bolts to detach the chain guideA from the body.

G) Remove the guide roller and the roller pin from thechain guide.

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3.5 Disassembly of the Motor

A) Turn the hoist over so that fan cover is facing up.Remove the socket bolts to detach the fan cover fromthe motor frame.

����� Setting the hoist up on woodenblocks will accommodate the gear shaft, whichextends out past the body.

B) Remove the snap ring and fan washer.

C) Remove fan. If fan does not come off easily, use apulley remover. Insert the "arms" of the pulley-remover into the holes in the fan to remove it.

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D) Remove the key (small square metal insert thatkeeps the fan in line with the motor) and the “O” ring.

E) Remove the socket bolts on the motor coverassembly.F) Using a plastic or rubber mallet and a screwdrivertap the cover evenly on each side to release themotor brake assembly from the motor frame. Prygently under the recesses the tabs to free the coverassembly.

G) Remove rotor and brake assembly.����� For convenient removal, rotate

the motor cover tabs so that they extend beyond thebody as pictured to the left and lift firmly upward onthe tabs.

����� Carefully remove motor coverwith brake drum, motor shaft and rotor. Damage tostator windings may result if rotor is allowed to fall ordrop against motor frame.

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H) Remove the socket bolts and loosen the motorframe/stator assembly by lightly tapping the base ofthe assembly with a plastic or rubber mallet. Toseparate, pry gently at the square notch on the side ofthe body. Pull off the motor frame/stator assemblyfrom the body.

����� Take precautions toprevent damaging the lead-wires of themotor/stator while pulling the unit off of the bodysection. Wiring must slide through the bodysection during removal.

I) Remove the packing gasket M.

����� If damaged, the packing gasketM will have to be replaced with a new gasket duringreassembly.

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3.6 Disassembly of the Body

A) Remove the snap ring retaining the pinion to thebody.

B) Pull out the pinion together with the bearing bylightly tapping the pinion from the direction of thegear case with a plastic or rubber mallet.

C) Remove the socket bolts to detach the bearingholder from the body.

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D) Remove the load sheave together with thebearing and the oil seal by lightly tapping in the samedirection as the pinion.

E) Remove the snap ring and take out all bearingsand oil seals from the body.

F) Remove the screws to take out chain guide B.

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3.7 Disassembly of the Motor Brake

A) Flatten the claw of the lock washer using a smallscrewdriver.

B) Loosen nut by lightly tapping a notch on the nutwith a screwdriver and mallet. Remove the nut byturning.

����� Pushing down on the motorbrake cover releases the spring tension making thenut easier to remove. Then remove the lock washer;spacer and motor cover assembly in this order.

C) Remove the collar M, coned disc spring, brakedrum assembly, brake spring, and thrust collar.

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D) Clamp the pull-rotor and the rotor together withtwo vises to remove the thrust disc.

E) Remove the pull rotor and the coned disc spring

������� Inspect all parts referring to Appendix A for wear measurements and criteria beforereassembly. Replace all parts that do not meet Appendix A criteria.

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4.0 Hoist Reassembly

4.1 Reassembly of the Motor Brake

������ If any part is judged to be outside of discard criteria during the check, do not use it forreassembly.

- Fasten bolts and nuts properly.- Ensure that all split pins are installed properly.

����� Make sure that the brake gap is inspected and adjusted.

A) Put the coned disc spring and the pull rotor (makesure of the direction) on to the rotor assembly. Withtwo vises clamp the rotor and the pull rotor together,and insert the thrust disc.B) Next, put the thrust collar, brake spring and brakedrum assembly on to the rotor assembly.

C) Assemble the four coned disc springs M, and addthem (make sure of their direction) to the rotorassembly.

D) Install collar M and the motor cover assembly, andassemble the spacer and the lock washer in thisorder.

Note: If spacers and collars are mixed, consultthe table below for part dimensions to determinethe correct spacer and collar M part placement.

SPACER/COLLAR M – PARTS DIFFERENTIATIONSPACER COLLAR M

HOIST TYPE PARTNUMBER

OUTSIDEDIAMETER

IN (mm)

PARTNUMBER

OUTSIDEDIAMETER

IN (mm)

001H, 003S,005L, 003H,005S, 010L,

010M

ES216S005 1.10 (28) ES192005S 1.00 (25.4)

010S, 15S,020L, 020M,

030CES216S010 1.18 (30) ES192010S 1.07 (27)

020S, 025S,030L, 030S,

050LES216S015 1.575 (40) ES192015 1.49 (38)

A

B

C

D

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E) Tighten the nut until the break gap (a gap betweenthe pull rotor and the brake drum) becomes the equalto the value specified in the Appendix A, Table 6-3.Confirm the gap with a feeler gauge.F) After confirmed, bend up the claw of the lockwasher into the notch of the nut. (If the notch of theadjusting nut and the claw of the nut washer do notmeet, turn the nut slightly in tightening direction sothat the claw gets into the nearest notch.)

����� If the gap becomes0.047”(1.2mm) or larger for those models with aproper gap of 0.020”(0.5 mm) and 0.059”(1.5 mm) forthose models with a proper gap of 0.032”(0.8 mm)respectively, the brake may drag or functionimproperly when the hoist is operated.

4.2 Partial Assembly of the Chain Guide

A) Install the guide roller and the roller pin.

4.3 Reassembly of the Body

A) Mount the chain guide B to the body (“A” NER or“B” ER) with machine screws. Ensure that screwsare adequately tightened.

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B) Prepare the bearing for the mechanical brakegear set or friction clutch set into the body section.

C) Put a new oil seal on the bearing, and insert theminto the body section from the gear-case side using aproperly sized ball bearing or oil seal driver. Use carewhile installing to prevent damaging them.After assembly, apply machine oil onto the entirecircumference of the lip. Using snap ring pliers inserta new snap ring with its sharp edge up (away frombearing). Check the snap ring fit. Make sure that thesnap ring is properly seated in the groove.

D) Put an oil seal on to the load sheave. Use aproperly sized ball bearing or oil seal driver to preventdamage to the seal. After assembly, apply machineoil onto the entire circumference of the lip.

E) Put the body section on wooden blocks and insertthe load sheave by using a ball bearing or oil sealdriver and lightly tapping with a plastic or rubbermallet.

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F) Put the pinion assembly (includes bearing) on thebearing holder and insert by lightly tapping with aplastic or rubber mallet.

G) Using a snap ring pliers, install a new snap ringwith its sharp edge up (away from bearing). Checkthe snap ring fit. Make sure that the snap ring isproperly seated in the groove.

H) Apply a thin and uniform layer of liquid sealant onthe surface of the bearing holder that contacts thebody. Install the bearing holder and pinion assemblyin the body. Apply thread-locking adhesive to thesocket bolts prior to installing.

I) Apply a thin and uniform layer of high temperaturegrease to the internal spline on the end of the pinion.

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4.4 Reassembly of the Motor

A) Place a new packing M on the surface of thebody section where the motor frame/statorassembly is to be mounted, then bundle the lead-wires of the motor with a electrical tape and passthem through the body section. Make sure lead-wires are not pinched between the body and thestator assembly. Mount the motor frame/statorassembly on to the body section such that theHarrington nameplate is located on the top hookside. Make sure the set pin is already installed.

B) Apply thread-locking adhesive to the socketbolts that connect the motor frame/stator assemblyto the body section and tighten the socket bolts.C) Apply liquid sealant to edge of motor coverwhere it mates to the motor frame. Insert themotor brake assembly into the motor frame/statorassembly.

����� Guard against bumping orscraping the stator windings while installing themotor brake and rotor.

D) Apply thread-locking adhesive to the socketbolts, and fasten the motor brake assembly andthe motor frame/stator assembly together. Checkthat the orientation of the motor cover leavesspace for the fan cover bolts.

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E) Slide the key into the motor shaft of the motorbrake assembly.F) Align the notch in the fan with the key on themotor shaft and press the fan onto the shaft. If thefit is too tight, lightly tap the place indicated in thefigure with a plastic or rubber mallet to install thefan.

G) Insert the fan washer and using snap ringpliers, install a new snap ring with its sharp edgeup. Check the snap ring fit. Make sure that thesnap ring is properly seated in the groove.H) Using socket bolts with star lock washers,connect the fan cover and the motor frame/statorassembly together. Make sure that the fan coverdrain hole is facing down towards the chain guide.

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4.5 Reassembly of the Load Chain

A) Reinstall the guide roller and the roller pin on thechain guide A.B) Reinstall the limit lever S (an upper limit switchtype) or the limit lever assembly (an upper/ lower limittype) on the chain guide A (AL).

C) Install the socket bolts to connect the chain guide Ato the body.D) Reinstall the limit lever pin, the lever coupling, andthe limit lever collar on the limit lever S (an upper limitswitch type) or the limit lever assembly (an upper/lower limit switch type).

E) If hoist is equipped with upper limit or an upper/lower limit switch reinstall the split pin and reinsert thelimit lever pin in the lever coupling.

F) Set up the load chain for installation such that thewelded side of the chain link runs on the outside of theload sheave. In addition, start by inserting a horizontallink first (a vertical link for the capacity of 5 tons orlarger).G) With the chain guide facing up, insert the loadchain into the chain guide from the load side. Wind upthe chain by turning the load sheave gear (not thespline) with your hand to pass it through to the otherload chain exit. Turn the hoist over to allow the loadchain to pass through the no load side exit.

H) Double-check the direction of the load chain. Thereshould be no twisting of the load chain.

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1/8 to 3 Ton Upper Limit Switch Only I) The quantity and location of the chain componentsincluding cushion rubbers, chain springs and strikerplates depend on the hoist model, capacity and limitsswitches. Never operate the hoist with incorrect,missing or damaged chain components.J) For hoists with an Upper Limit Switch only, refer tothe hoist's nameplate, Chain Stopper PlacementTable, and Figures to the left and ensure that all chaincomponents are in the correct location and properlyinstalled.

K) For further information on installing the stopper,and cushion rubber or chain spring refer to section 3.2in the Owner’s Manual for specific instructionsapplicable to your hoist.

5 Ton Upper Limit Switch Only

Chain Stopper Placement TableCapacity Code

Without Chain Container

With Chain Container

001HD, dual speed with optional upper/lower limit switch

25th link from the free end

3rd link from the free end

001H, 003S, 003H, 005L, 005S, 010L, 010S, 015S, 020L

15th link from the free end

3rd link from the free end

020S, 025S, 030L, 030S, 050L

13th link from the free end

3rd link from the free end

1/8 to 5 Ton Upper/Lower Limit Switch L) For hoists with Upper and Lower Limit Switches,refer to the illustrations at the left…

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8 to 20 Ton Stopper and End Connections

M) For 8 to 20 Ton hoists without a chain container,the free end of the chain is attached to the hoist bodyas shown in Figure at right. Connect the “no load” endof the chain to Chain Guide A with an End Wire or EndSuspender and the pre-installed socket bolt and locknut. Make sure the chain remains free of twists andthe chain Stopper is installed on the correct link. Referto table below for proper placement of Stopper.

Chain Stopper Placement

Capacity CodeWithout Chain Container

With Chain Container

080S, 100L, 100S, 150S, 200S

9th link from the free end

3rd link from the free end

1/8 to 5 Ton Chain Container Installation N) For hoist on which the optional canvas chaincontainer is used, install it on the hoist body as shownin the figures to the right. In this case the free end ofthe chain is not attached to the hoist body and thechain stopper is installed on the third link from the freeend. To place the chain into the chain container, feedthe chain into the chain container beginning with thefree end. Take care to avoid twisting or tangling thechain.

8 to 20 Ton Chain Container Installation O) NEVER put all the chain into the container at once.Lumped or twisted chain may:Upper Limit Switch Only - jam against the hoist bodyactivating the friction clutch and potentially damagingthe chain.

Upper and Lower Limit Switch (Optional) - activate thedown limit switch and stop the hoist during lowering.

P) When using an optional steel chain container, referto the assembly drawing provided with the containerfor correct assembly and attachment.

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• PRECAUTIONS FOR ASSEMBLING DOUBLE FALL TYPE LOAD CHAIN (5 – 20 TON)

A) For hoist capacities 5-20 Ton, insert the loadchain from the no load side. Also, insert a verticallink first into the chain guide.B) For placement of the chain spring, stopper, andcushion rubber or chain spring see Owner’s Manual1/8 – 5 Ton & 8-20 Ton, Section 3.2.

C) Pass the chain spring to the top of the bottomhook.

D) Connect the load side chain end to theconnection yoke using the chain pin, slotted nut andsplit pin. Make sure the load chain is not twisted.

E) For installation instructions for the stopper on theload chain see Owner’s Manual 1/8 – 5 Ton & 8-20Ton, Section 3.2.

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4.6 Reassembly of the Gear Case and Gear Parts

A) Flip the hoist body such that the fan side is down.Insert the load gear on to the load sheave andattach with a new snap ring with its sharp edge up.B) Ensure that the snap ring is properly seated inthe groove.

• FOR ER ONLY

A) Insert the pawl spring and pawl onto the pawlshaft. Make sure that the pawl spring is insertedinto the restraining hole in the body and clips tothe top of the pawl. Fasten with a new snapring. Make sure of the direction so that the pawlproperly engages the ratchet (see illustrationbelow).

38

B) Pre-assemble the mechanical brake with frictionclutch complete set (composed of the gear, brakeholder, ratchet, friction clutch assembly, thrust disc,and thrust collar). After confirming the engagementof the ratchet wheel and pawl, connect themtogether.

C) Install the friction clutch assembly and attach theset spring (This step is not necessary formechanical brake with friction clutch type)

D) For NER, insert new oil seal into the gear caseand press it into the gear case. After assembly,apply machine oil on the entire circumference of thelip. (This step is not necessary for mechanical brakewith friction clutch type)

E) For three gear hoists, reinstall the gear platesocket bolt and spring washer checking the positionof set pin S. Place bearing on gear plate, and thenthe gear B assembly, thrust plate, needle bearingand ball bearing.

39

F) Place a new gear case packing and assemblethe gear case by lightly tapping with a plastic orrubber mallet. Make sure that the set pin is alreadyinstalled.

����� Prevent pinching lead-wireswhile connecting the gear case to the body.

G) Hand tighten socket bolts to connect the gearcase to the body section, and then tighten bolts in adiagonal sequential manner.

H) Insert the connection shaft and the fixing shaftthrough the top hook (connection yoke).I) Retain the connection shaft with plate A.

40

4.7 Reassembly of the Controls Unit

A) Reconnect lead-wires of the motor.B) Check the wiring using the wiring diagram listed inAppendices or Owner’ Manual.

C) Close the plate and secure the plate screws.

D) Hook the cover suspender C connected to thecontroller cover onto the cover suspender A and Bconnected to the gear case.

E) If damaged, replace the controller cover packingwith a new one and connect the controller cover withsocket bolts.F) Insert the plug 5P of the push button cord into thesocket 5P and connect the cord support wire to thegear case.

G) Insert the plug 4P of the power supply cable to thesocket 4P and connect the power supply cable to thecable holder.

H) Reinstall the chain container on to the body, if thehoist was equipped with one. Or, install load chainend wire or end suspender (Refer to the Owner’sManual 1/8 – 5 Ton & 8-20 Ton, Section 3.2 forinstalling the container, end wire or end suspender).

I) Install the limit lever S (an upper limit switch type)or the limit lever assembly (an upper/ lower limit type)on to the chain guide A (AL).J) Install the limit lever pin, the lever coupling, andthe limit lever collar on to the limit lever S (an upperlimit switch type) or the limit lever assembly (anupper/ lower limit switch type).

K) If hoist is equipped with upper limit or an upper/lower limit switch install the split pin and re-insert thelimit lever pin on to the lever coupling.

41

4.8 Checking Hoist Operation

����� Refer to applicable paragraphs of Owner’s Manual, Electric Chain Hoist, ER and NERSERIES 1/8 Ton through 5 Ton Capacity, and Owner’s Manual Supplement, Electric Chain Hoist, ER and NERSERIES 8 Ton through 20 Ton Capacity of sections 3.0 and 6.0 prior to operating the hoist.

A. Fill gear oil through the fill plug before starting operational checks.

Amount of Gear Oil

Capacity Code Quarts Liters

001H, 003S, 005L 0.74 0.7

003H, 005S, 010L 1.06 1.0

010S, 015S, 020L 1.80 1.7

020S, 025S, 030L,030S, 050L 3.17 3.0

Oil Plug LocationsNER Gear Oil:� Harrington standard: Bonnoc M260 (NIPPON OIL)� Acceptable equivalent: Meropa 320 (TEXACO)� Acceptable equivalent: Meropa 320 (CALTEX)

ER Gear Oil:� Harrington standard: Antoil super B (NIPPON OIL)� Acceptable equivalent: Meropa No.68 (TEXACO)

����� The ER (with mechanical load brake/friction clutch) uses different gear oil than the NER (with frictionclutch). DO NOT use any oil or quantity other than that specified.

������� Using an incorrect type/grade of gearbox oil or the wrong quantity of oil may prevent the frictionclutch from working properly and may affect the ability of the hoist to hold the load. Refer to table above for the correctoil and quantity.

B. Power ON: Conduct lifting and lowering operations with no load, and check if:

• The hoist lifts or lowers as intended.• The motor rotates properly.• The gear rotates properly.• The brake engages when stopped and the motor stops immediately.• The upper/ lower limit switch works properly (only for a model equipped with a limit switch).

If proper operations are confirmed without load, set a rated load and repeat the operational test.

C. Dynamic Load Test

• A dynamic load test must be performed on the hoist in accordance with ANSI B30.16.

42

5.0 Electrical Troubleshooting Procedure

�������

HAZARDOUS VOLTAGES ARE PRESENT IN THE HOIST AND IN CONNECTIONS BETWEENCOMPONENTS.Before performing ANY troubleshooting on the equipment, de-energize the supply of electricity to the equipment,and lock and tag the supply device in the de-energized position. Refer to ANSI Z244.1, “Personnel Protection -Lockout/Tagout of Energy Sources.”

Only Trained and competent personnel should inspect and repair this equipment.

The following operations provide guidance in the electrical troubleshooting and repair of the ER/NER electricchain hoist. These operations are best performed prior to hoist disassembly.

5.1 Principle of OperationThe electrical components of the hoist are connected in a series circuit configuration. In a seriescircuit all of the components are connected together one after another. The series circuit iscompleted when all of the switches and components in the circuit are closed and energized. Ifthere is a disconnect or a component is not energized in the series circuit the hoist will notoperate.

Three-phase power is introduced into the hoist through the power supply cord to the contactor and thetransformer. The contactors are used to control the hoist and/or trolley operation. The transformerlowers and converts the voltage to 110-volt single phase. The single-phase power is used in thependant control circuit. The lower control voltage meets the requirements of ASME and OSHA. Oncethe contactor is energized, the three-phase power flows to the hoist motor allowing hoist operation.

5.2 Design ConceptThe hoist electrical circuit is divided into a power circuit and a control circuit. The electrical componentsare arranged on a hinged plate for repair and maintenance convenience.

5.3 Count/Hour Meter (C/H)The optional C/H Meter provides the means to compile a maintenance record. Using it with thefollowing tables also provides an indicator of when to replace components.

The C/H Meter located on the electrical control panel records the hoist's on time and the number ofstarts. To view the two values press the button on the C/H Meter one time. The display will first showan "H" and a 4-digit number, which is the hoist's total on time (lifting/lowering) in hours. After 3seconds, the display will automatically change to a 6-digit number indicating the number of hoist startsbased on the Down contactor activity. Refer to Figure 5-1.

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Figure 5-1 Count/Hour Meter

5.3.1 Contactor UseThe C/H Meter can be used in conjunction with the amount of hoist “jogging” to estimate when thecontactor(s) should be replaced. “Jogging” is defined as short or quick hoist operations required toposition the load hook. It is accomplished by repetitively pressing the pendant hoist control buttons tomove the load hook in small increments. Refer to Table 5-1.

Table 5-1 Criteria for Recommended Contactor Replacement

Jogging During Normal Operation

Rating Approximate Jogging Frequency

Change Contactor After:(Starts)

Low Jogging is rare. 1,000,000

Medium During 25% of operations/lifts. 500,000

High During 50% or more of operations/lifts. 200,000

5.3.2 Gear Oil ChangingThe C/H Meter can be used in conjunction with the average load lifted by the hoist to estimate when thegear oil should be changed. Refer to Table 5-2.

Table 5-2 Criteria for Recommended Gear Oil Replacement

Loading During Normal Operation

Rating Average % of Rated CapacityChange Gear Oil After:

(Hours)

Light 0 to 33% 360

Medium 33 to 67% 240

Heavy 67 to 100% 120

5.4 Additional Tools Required• Volt-Ohm-Meter (VOM)

• Clamp type Ammeter (Amp Clamp)

44

5.5 Troubleshooting/Repair

5.5.1 Lower/Lift Direction Notice

1) ������� The hoist must be connected to the power source so that its direction ofoperation corresponds to the up-and-down commands issued from the pendant control; i.e. pushing theup button must cause the hoist to lift the load. If the hoist does not operate correctly, shut off andbefore proceeding, ensure that the electrical supply for the hoist or trolley has been de-energized(disconnected). Lock out and tag out in accordance with ANSI Z244.1 “Personnel Protection -Lockout/Tagout of Energy Sources”.

2) Disconnect and switch any two of the three input power leads at the power source to correct thehoist’s motor phasing. Do not change any of the power connections inside the hoist body.

5.5.2 Hoist Motor Phasing/Single Phasing1) A hoist will not function normally if the incoming power is not on all three (3) conductors, whichis a condition called “single-phasing”. “Single-phasing” will cause damage to the hoist.

5.5.3 Hoist Fails To Operate1) Check Incoming Power

Hoist Data Plate

Use data that pertains to your particular hoistinstallation; motor wiring can be connected for avariety of voltages.

45

Voltage Measurement

A) ������ Hazardous voltages arepresent in the control box, other electricalcomponents, and connections between thesecomponents. Only trained and competentpersonnel should inspect and repair thisequipment.

B) Before proceeding, ensure proper lock out andtag out procedures in accordance with ANSI Z244.1“Personnel Protection -Lockout/Tagout of EnergySources” are followed.

C) Check the incoming power source to ensure thateach phase measures within 10% of the voltagelisted on the data plate on the outside of the hoist.Refer to paragraph 5.5.3 1).

C) If the voltage varies more than 10% of the ratedvalue, the hoist may not function normally. A hoistwill not function normally if the incoming power is notpresent on all three (3) conductors, which is acondition called “single-phasing”.

2) Check Power Supply Cord

Continuity Measurement

A) Check the power supply (SO) cord continuity.Continuity failures may occur in the power supplycord because of the amount of motion that theconductors encounter. Over time the conductorsbecome brittle and break.

B) On one end of the power supply cord is a four (4)pin connector that connects to the hoist. The otherend of the power supply cord connects to an outsidepower source. Check the power supply conductorsby pulling the 4 pin disconnect plug out of the hoistand disconnecting the other end from the hard-wiredsource. Using a VOM test the continuity of eachconductor.

B) Also, test the continuity with the other conductorsto ensure that the reading is correct and that the wireis not “shorted” to another conductor.

46

3) Check Contactor(s)

Contactor Voltage Measurement

A) ���� Taking a reading from line toground will not yield the proper voltage reading dueto the use of phase converters or deltas. Onlymeasure line to line.

B) Power On – High Voltage. With the hoistpowered ON check the voltage on the contactor.Test the voltage line to line. Ensure that the voltagemeasurements match the voltage listed on the dataplate, which is on the outside of the hoist. Refer toparagraph 5.5.3 1).

C) Contactor Coil –Verifiy that the contactor coil is notdamaged or open by measuring the resistancebetween A1 and A2 on both coils. It should not bean “open” circuit.

Contactor

A) Power Off – Make sure that there are no cracks orother damage to the contactor. Make sure that thecontactor operates smoothly by pushing the testbutton with a screwdriver.

B) Check each contact point for continuity whilemechanically operating the contactor. Observe thecontact points “making” and “breaking”.

C) Make sure that no contact is burned anddamaged. This is exhibited by blackening or pitting.If this or any results of “arcing” are observed, replacethe contactor.

47

4) Check Transformer

Transformer

A) De-energize (disconnect) the main switchsupplying power to the equipment, and lock andtag the main switch in the de-energized position.

B) Verify that the transformer fuse is not open.

Transformer Continuity Test

A) Isolate or disconnect the transformer. Using theVOM verify the continuity of the primary and thesecondary transformer windings. The resistancevalue should be small. If very large, indicating anopen circuit, replace transformer.

B) Next, reconnect all wiring, reenergize all circuitsand check the voltage on the secondary (lowvoltage) side of the transformer. It should measure+/- 10% of rated voltage.

C) Check for improper electrical connections byreferring to the wire diagram (Appendix C).

D) Check for loose or broken connections.

5) Check Incoming Current.

Current Measurement

Using a clamp type ammeter (amp clamp) checkeach of the three-phase lines at the main disconnector switch, one at a time. The amperage should beapproximately equal for each phase and the samefor values listed on the data plate. It will be a littleunder the rating on the plate if it is cold and close toor a little over to the data on the plate if it is hot.

48

6) Check the Motor Windings (Current Draw).

Hoist Motor Connections

With the hoist powered ON measure the currentdraw at the motor connections on the terminal stripusing the clamp type ammeter (amp clamp). Ensurethat the current measurements match those listed onthe data plate, which is on the outside of the hoist.

7) Check Pendant Cable (SO Cord)

Continuity Check

A) Check the pendant (SO) cord continuity.Continuity failures may occur in the pendant cablebecause of the amount of motion that the conductorswithin the SO Cord encounter. Over time theconductors may become brittle and break. Using theVOM, check the continuity of the pendant cableconductors. Remove the pendant cable plug fromthe hoist.

B) At the pendant plug, test for continuity betweenthe common conductor, pin 4 and the UP (pin 2) andDOWN (pin 1) conductors. A “short” or lowresistance measurement should be observed whendepressing the pendant button and an “open” or highresistance measurement when the button isreleased. Also, test the continuity with the otherconductors to ensure that the reading is correct andthat there is not a “short” to another conductor.

49

8) Check Limit Switch(es)

Limit Switch

A) Power On Method – While operating the hoist inthe lifting direction, push up on the load side of thelimit switch. The hoist should stop lifting.

B) If there is an optional lower limit switch, operatethe hoist in the lowering direction, push up on the no-load side the limit switch. The hoist should stoplowering. Malfunctioning limit switch(es) should bereplaced.

Limit Switch

A) Power Off Method – For the Up direction, placethe VOM probes across limit switch terminals A andB. Push the limit lever UP, the VOM should measurean “open” circuit and in the DOWN direction a“closed” circuit.

B) If there is an optional lower limit switch, place theVOM probes across limit switch terminals D and C.Push the limit lever UP, the VOM should measure an“open” and in the DOWN direction a “closed” circuit.

C) Refer to the appropriate wiring diagram inAppendix C.

9) Check Count Hour (C/H) Meter

If the C/H Meter is not operating and there is power to the hoist, using the VOM measure the voltageacross the C/H Meter. If single-phase voltage is measured and the C/H Meter is not functioning, theC/H Meter is defective and should be replaced. Refer to paragraph 5.3.

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10) Check Hoist Motor

Motor Terminals U1, V1 and W1

A) Motor Winding Resistance Value. Using theVOM, the resistance measurement betweenterminals U1, V1 and W1 should be the equal.

B) Motor Voltage (+/-10% Range). Check the motorvoltage across terminals U1, V1 and W1 to ensurethat each phase measures within 10% of the voltagelisted on the data plate on the outside of the hoist. Ifthe voltage varies more than 10% of the rated value,the hoist may not function normally. A hoist will notfunction normally if the incoming power is not presenton all three (3) conductors, which is a conditioncalled “single-phasing”.

11) Check for Pinched Motor Leads

Wires at Hinged Panel

Although a rare occurrence, the motor leadsmay become pinched somewhere within thehoist This may cause a wire breakage or a“short”.

51

12) Check Hoist Motor Thermal Overload

Thermal Overload Continuity Test

A) The thermal overload is a normally closed switch.The switch opens when there is an overloadcondition.

B) With the hoist power OFF measure the continuitybetween plug terminals 1 and 1B.

C) Plug terminal 1 is located at the hinged panel bythe hoist contactors. Plug terminal 1B is located onthe other side of the hinged panel near the hoist limitswitch. A closed circuit measurement, a “short” orlow resistance measurement, indicates that thethermal switch has not been activated. An opencircuit measurement, an “open” or high resistancemeasurement, indicates that the thermal overloadswitch has been activated by a thermal overloadcondition or it is defective.

D) If a thermal overload exists it must be correctedand the continuity test performed. If there is nothermal overload and the thermal overload switchmeasures “open”, the switch should be replaced.

E) Perform the continuity test and corrections untilthe thermal switch performs correctly.

13) Check Hoist Motor Brake

Refer to Section 6.3 of the Electric Chain Hoist ER and NER Series Owner’s Manual.

14) Check Hoist Fusing

Time Delay Fuse – The hoist's power supply should be equipped with overcurrent protection such as fuses,which should be selected for 110% to 120% of total listed full load amperage, and should be dual element time-delay fuses. Refer to the motor nameplate for the full load amperage draw. Dual element time-delay fuses arerecommended because of the large “in-rush” currents encountered with motors.

Large Amperage Fuse – If dual element time-delay fuses are not available, a large amperage fuse may be usedbut must be sized higher than the in-rush current. In-rush currents may be as high as three (3) times theoperating current.

52

5.5.4 Wiring Diagram – Select the appropriate wiring diagram in Appendix C

5.5.5 Troubleshooting Guide – See Appendix C

Appendix A53

Appendix A• Inspection Methods, Criteria and Wear Measurements• For 1/8 Ton through 5 Ton Capacity• Section references are to the Owner’s Manual, Electric Chain Hoist,

ER and NER Series

Table 5-3 Hoist Inspection Methods and Criteria

Item Method Criteria Action

Functionaloperatingmechanisms.

Visual, Auditory Mechanisms should be properly adjusted andshould not produce unusual sounds whenoperated.

Repair or replaceas required.

Limit Switch Function Proper operation. Actuation of limit switchshould stop hoist.

Repair or replaceas required.

Limit LeverAssembly

Visual, Function Lever should not be bent or significantly worn andshould be able to move freely.

Replace.

Braking SystemOperation

Function Braking distance with rated capacity should notexceed 3% of the lifting speed (approximatelytwo chain links).

Repair or replaceas required.

Hooks - SurfaceCondition

Visual Should be free of significant rust, weld splatter,deep nicks, or gouges.

Replace.

Hooks - Frettingwear

Measure The "u" and "t" dimensions should not be lessthan discard value listed in Table 5-4

Replace.

Hooks - Stretch Measure The "k" dimension should not be greater than1.15 times that measured and recorded at thetime of purchase (See Section 3.6). Ifrecorded "k" values are not available for hookswhen new, use nominal "k" values from Table5-4.

Replace.

Hooks - BentShank or Neck

Visual Shank and neck portions of hook should befree of deformations.

Replace.

Hooks - YokeAssembly

Visual Should be free of significant rust, weld splatter,nicks, gouges. Holes should not be elongated,fasteners should not be loose, and there shouldbe no gap between mating parts.

Tighten or replaceas required.

Hooks - SwivelBearing

Visual, Function Bearing parts and surfaces should not showsignificant wear, and should be free of dirt,grime and deformations. Hook should rotatefreely with no roughness.

Clean/lubricate, orreplace asrequired.

Hooks - IdleSheave and Axle(Bottom Hook onDouble Fall Hoist)

Visual, Function Pockets of Idle Sheave should be free ofsignificant wear. Idle Sheave surfaces shouldbe free of nicks, gouges, dirt and grime.Bearing parts and surfaces of Idle Sheave andAxle should not show significant wear. IdleSheave should rotate freely with no roughnessor significant free play.

Clean/lubricate, orreplace asrequired.

Appendix A54

Table 5-3 Hoist Inspection Methods and Criteria

Item Method Criteria Action

Hooks - HookLatches

Visual, Function Latch should not be deformed. Attachment oflatch to hook should not be loose. Latch springshould not be missing and should not be weak.Latch movement should not be stiff - whendepressed and released latch should snapsmartly to its closed position.

Replace.

Load Chain -Surface Condition

Visual Should be free of rust, nicks, gouges, dentsand weld splatter. Links should not bedeformed, and should not show signs ofabrasion. Surfaces where links bear on oneanother should be free of significant wear.

Replace.

Load Chain - Pitchand Wire Diameter

Measure The "P" dimension should not be greater thanmaximum value listed in Table 5-5. The "d"dimension should not be less than minimumvalue listed in Table 5-5.

Replace. InspectLoad Sheave (andIdle Sheave fordouble fall hoist).

Load Chain -Lubrication

Visual, Auditory Entire surface of each chain link should becoated with lubricant and should be free of dirtand grime. Chain should not emit crackingnoise when hoisting a load.

Clean/lubricate(see Section 6.0).

Load Chain -Reeving

Visual Chain should be reeved properly through LoadSheave (and Idle Sheave for double fall hoist) -refer to Section 6.4. Chain, Chain Springs,Cushion Rubbers, Striker Plates, and Stoppersshould be installed properly - refer to Section3.2.

Reeve/Installchain properly.

Housing andMechanicalComponents

Visual, Auditory,Vibration,Function

Hoist components including load blocks,suspension housing, chain attachments,clevises, yokes, suspension bolts, shafts,gears, bearings, pins and rollers should be freeof cracks, distortion, significant wear andcorrosion. Evidence of same can be detectedvisually or via detection of unusual sounds orvibration during operation.

Replace.

Bolts, Nuts andRivets

Visual, Checkwith Proper Tool

Bolts, nuts and rivets should not be loose. Tighten or replaceas required.

Motor Brake Measure, Visual Motor brake gap should be adjusted to thedistance shown in Table 6-3 before measuringthe brake wear. Brake lining dimension “A”should not be less than discard value listed inTable 5-6. Refer to Section 6.3 for gainingaccess to motor brake and for adjustment andinspection procedures. Braking surfacesshould be clean, free of grease/oil and shouldnot be glazed.

Adjust, Repair orReplace asrequired.

Contactor Contacts Visual Contacts should be free of significant pitting ordeterioration. On hoists equipped withCount/Hour Meter check the contactor cycles –refer to Section 6.1.

Replace.

Appendix A55

Table 5-3 Hoist Inspection Methods and Criteria

Item Method Criteria Action

Load Sheave Visual Pockets of Load Sheave should be free ofsignificant wear.

Replace.

Cushion Rubber Visual Should be free of significant deformation. Replace.

Chain Springs Visual Chain springs should be not be deformed orcompressed. Refer to Chain SpringDimensions chart on page 60.

Replace.

Pendant - Switches Function Depressing and releasing push-buttons shouldmake and break contacts in switch contactblock and result in corresponding electricalcontinuity or open circuit. Push-buttons shouldbe interlocked either mechanically orelectrically to prevent simultaneous energizingof circuits for opposing motions (e.g. up anddown).

Repair or replaceas necessary.

Pendant -Housing

Visual Pendant housing should be free of cracks andmating surfaces of parts should seal withoutgaps.

Replace.

Pendant - Wiring Visual Wire connections to switches in pendantshould not be loose or damaged.

Tighten or repair

Pendant - Cord Visual, ElectricalContinuity

Surface of cord should be free from nicks,gouges, and abrasions. Each conductor in cordshould have 100% electrical continuity even whencord is flexed back-and-forth. Pendant CordStrain Relief Cable should absorb all of the loadassociated with forces applied to the pendant.

Replace.

Pendant - Labels Visual Labels denoting functions should be legible. Replace.

Warning Labels Visual Warning Labels should be affixed to the hoist(see Section 1.2) and they should be legible.

Replace.

Hoist CapacityLabel

Visual The label that indicates the capacity of thehoist should be legible and securely attachedto the hoist.

Replace.

Appendix A56

Table 5-4 Top Hook & Bottom Hook Dimensions

“k” Measured When New:

Top: _________________________

Bottom: ______________________

"u" Dimensioninch (mm)

"t" Dimensioninch (mm)Capacity Code

*Nominal"k"

Dimensioninch (mm) Standard Discard Standard Discard

001H, 003S, 003H,005L, 005S 1.65 (42) 0.93 (23.5) 0.83 (21) 0.69 (17.5) 0.63 (16)

010L, 010S 1.97 (50) 1.22 (31) 1.10 (28) 0.89 (22.5) 0.79 (20)

015S 2.36 (60) 1.44 (36.5) 1.30 (33) 1.04 (26.5) 0.94 (24)

020L, 020S 2.46 (62.5) 1.57 (40) 1.42 (36) 1.14 (29) 1.02 (26)

025S 2.72 (69) 43.5 (1.71) 1.54 (39) 1.24 (31.5) 1.10 (28)

030L, 030S 2.95 (75) 1.87 (47.5) 1.69 (43) 1.36 (34.5) 1.22 (31)

050L 3.27 (83) 2.20 (56) 1.97 (50) 1.67 (42.5) 1.50 (38)

* These values are nominal since the dimension is not controlled to a tolerance.The "k" dimension should be measured when the hook is new - this becomes areference measurement. Subsequent measurements are compared to thisreference to make determinations about hook deformation/stretch. See Section 5.7,“Hooks – Stretch.

Appendix A57

Table 5-5 Chain Wear Dimensions

“P” Dimensioninch (mm)

“d” Dimensioninch (mm)Capacity Code

Standard Discard Standard Discard

001H, 003S, 2.97 (75.5) 3.02 (76.6) 0.22 (5.0) 0.18 (4.5)

003H, 005L, 005S 3.76 (95.5) 3.82 (96.9) 0.25 (6.3) 0.22 (5.7)

010L, 010S 4.76 (121.0) 4.91 (124.6) 0.31 (8.0) 0.28 (7.2)

015S, 020L, 020S 5.96 (151.5) 6.05 (153.8) 0.39 (10.0) 0.35 (9.0)

025S, 050L 6.75 (171.5) 6.85 (174.1) 0.44 (11.2) 0.40 (10.1)

030L, 030S 7.52 (191) 7.74 (196.7) 0.49 (12.5) 0.44 (11.3)

Appendix A58

Table 5-6 Motor Brake Wear Dimensions

������ Brake must be properly adjusted before measuring "A". See Section 6.3

"A" Dimension - inch (mm)

Single Speed Dual SpeedCapacity Code

Standard Discard Standard Discard

001H, 003S, 005L 0.67 (17) 0.61 (15.5) 0.67 (17) 0.61 (15.5)

003H, 005S, 010L 0.85 (21.5) 0.79 (20) 0.85 (21.5) 0.79 (20)

010S, 015S, 020L 0.89 (22.5) 0.83 (21) 1.06 (27) 1.00 (25.5)

020S, 025S, 030L, 030S,050L 0.83 (21) 0.77 (19.5) 1.54 (39) 1.48 (37.5)

Appendix A59

Table 6-3 Motor Brake Gap

Capacity Code Brake Gap (G)inch (mm)

001H, 003S, 005L, 003H, 005S,010L, 010S, 015S, 020L 0.020 (0.5)

020S, 025S, 030L, 030S, 050L 0.032 (0.8)

Figure 6-3 Chain Replacement

Appendix A60

Chain Spring Measurements

����� The chain spring gets compressed over time and if not replacedwill result in damage to the hoist body form motor drift.

������ For the 001H, 003S, 005L 003H, 010L, 015S -single and dualspeed hoists with just the upper limit switch there are No Springs.

Chain Spring Dimensions

Capacity CodeChain

DiameterInch (mm)

ainch (mm)

binch (mm)

cinch (mm)

dinch (mm)

Single Speed with Upper/Lower Limit Switch (standard)001H, 003S 0.20 (5) 0.87 (22) 4.72 (120) 0.63 (16) 0.55 (14)003H, 005L, 005S 0.25 (6.3) 1.06 (27) 5 (127) 0.51 (13) 0.43 (11)010L, 010S 0.31 (8) 1.30 (33) 3.94 (100) 0.35 (9) 0.28 (7)015S 0.39 (10) 1.59 (40.5) 3.35 (85) 2.95 (7.5) 0.22 (5.5)020L 0.39 (10) 1.59 (40.5) 2.76 (70) 0.26 (6.5) 0.18 (4.5)020S 0.39 (10) 1.59 (40.5) 3.35 (85) 2.95 (7.5) 0.22 (5.5)025S 0.44 (11.2) 1.77 (45) 2.95 (75) 0.26 (6.5) 0.18 (4.5)030L, 030S 0.49 (12.5) 1.95 (49.5) 3.15 (80) 0.26 (6.5) 0.18(4.5)050L 0.44 (11.2) 1.77 (45) 2.95 (75) 0.26 (6.5) 0.18 (4.5)

Dual Speed with Upper/Lower Limit Switch (standard)001H, 003S 0.20 (5) 0.87 (22) 4.72 (120) 0.63 (16) 0.55 (14)003H, 005L, 005S 0.25 (6.3) 1.06 (27) 5 (127) 0.51 (13) 0.43 (11)010L, 010S 0.31 (8) 1.30 (33) 3.94 (100) 0.35 (9) 0.28 (7)015S 0.39 (10) 1.59 (40.5) 2.76 (70) 0.26 (6.5) 0.18 (4.5)020L 0.39 (10) 1.59 (40.5) 3.35 (85) 2.95 (7.5) 0.22 (5.5)020S 0.39 (10) 1.59 (40.5) 6.30(160) 0.43 (11) 0.35 (9)025S 0.44 (11.2) 1.77 (45) 5.31 (135) 0.35 (9) 0.28 (7)030L, 030S 0.49(12.5) 1.95 (49.5) 5.71 (145) 0.33 (8.5) 0.26 (6.5)050L 0.44 (11.2) 1.77 (45) 5.31 (135) 0.35 (9) 0.28 (7)

Appendix B61

Appendix B• Inspection Methods, Criteria and Wear Measurements• For 8 Ton through 20 Ton Capacity

������ The information listed in this section is intended to supplementAppendix A. Section references are made to the Owner’s Manual, Electric ChainHoist ER and NER Series

Table 5-3 Hoist Inspection Methods and CriteriaUse this table in conjunction with Table 5-3 of the EROM. The entries in this table replace in their

entirety the corresponding entries in Table 5-3 of the EROM.

Item Method Criteria Action

Hooks - Frettingwear

Measure The "u" and "t" dimensions should not be lessthan discard value listed in Table 5-4

Replace.

Hooks - Stretch Measure The "k" dimension should not be greater than1.15 times that measured and recorded at thetime of purchase (See Section 3.6). Ifrecorded "k" values are not available for hookswhen new, use nominal "k" values from Table5-4.

Replace.

Load Chain - Pitchand Wire Diameter

Measure The "P" dimension should not be greater thanmaximum value listed in Table 5-5. The "d"dimension should not be less than minimumvalue listed in Table 5-5.

Replace. InspectLoad and IdleSheaves.

Load Chain –Reeving andEvening

Visual Chain should be reeved properly through Loadand Idle Sheaves - refer to Section 6.4.Chain, Chain Springs, Stoppers, and Chain Pinshould be installed properly - refer to Section3.2. For double body hoists, chain should beevenly distributed – equal lengths of chain ineach chain container or equal lengths of chainon no-load side of each hoist body.

Reeve/Installchain properly.

Lower hook untillower limit switchis activated onboth hoist bodies.

Motor Brake Measure, Visual Motor brake gap should be adjusted to thedistance shown in Table 6-3 of the EROMbefore measuring the brake wear. Brake liningdimension “A” should not be less than discardvalue listed in Table 5-6. Refer to Section 6.3of the EROM for gaining access to motor brakeand for adjustment and inspection procedures.Braking surfaces should be clean, free ofgrease/oil and should not be glazed.

Adjust, Repair orReplace asrequired.

Appendix B62

Table 5-4 Top Hook & Bottom Hook Dimensions

“k” Measured When New:

Top:_________________________

Bottom:______________________

"u" Dimensioninch (mm)

"t" Dimensioninch (mm)Capacity Code

*Nominal"k"

Dimensioninch (mm) Standard Discard Standard Discard

080S, 100L, 100S 4.72(120) 2.87(73) 2.60(66) 1.89(48) 1.69(43)150S 5.04(128) 3.43(87) 3.07(78) 2.36(60) 2.13(54)200S 5.57(141.5) 3.92(99.5) 3.54(90) 2.76(70) 2.48(63)

* These values are nominal since the dimension is not controlled to atolerance. The "k" dimension should be measured when the hook is new -this becomes a reference measurement. Subsequent measurements arecompared to this reference to make determinations about hookdeformation/stretch. See Section 5.7, “Hooks - Stretch”.

Appendix B63

Table 5-5 Chain Wear Dimensions

“P” Dimensioninch (mm)

“d” Dimensioninch (mm)Capacity Code

Standard Discard Standard Discard

080S, 100L, 100S,150S, 200S 6.75 (171.5) 6.85 (174.1) 0.44 (11.2) 0.40 (10.1)

Table 5-6 Motor Brake Wear Dimensions

������ Brake must be properly adjusted before measuring "A".

See Section 6.3 of EROM

"A" Dimension - inch (mm)

Single Speed Dual SpeedCapacity Code

Standard Discard Standard Discard

080S, 100L, 100S, 150S,200S 0.83 (21) 0.77 (19.5) 1.54 (39) 1.48 (37.5)

Appendix B64

Table 6-3 Motor Brake Gap

Capacity Code Brake Gap (G)inch (mm)

080S, 100L, 100S, 150S, 200S 0.032 (0.8)

Figure 6-4 Chain Replacement for 100S, 150S, 200S

Appendix B65

Chain Spring Measurements

����� The chain spring gets compressed over time and if not replaced willresult in damage to the hoist body from motor drift.

Chain Spring Dimensions

Capacity CodeChain

DiameterInch (mm)

ainch (mm)

binch (mm)

cinch (mm)

dinch (mm)

Single Speed with Upper/Lower Limit Switch (standard)

080S, 100L,100S, 150S, 200S 0.44 (11.2) 1.77 (45) 6.30 (160) 0.47 (12) 0.39 (10)

Dual Speed with Upper/Lower Limit Switch (standard)

080S, 100L,100S, 150S, 200S 0.44 (11.2) 1.77 (45) 6.30 (160) 0.47 (12) 0.39 (10)

Appendix C66

Appendix C• Electrical Trouble shooting Guide and Wiring Diagram.

Table 7-1 Troubleshooting Guide

Symptom Cause Remedy

Power supplyreversed phased

Switch 2 of the 3 power supply cord wires at the powersource.Hoist moving in

wrong direction Improper electricalconnections Refer to wiring diagram and check all connections.

Loss of power Check circuit breakers, switches, fuses and connections onpower lines/cable.

Wrong voltage orfrequency

Check voltage and frequency of power supply against therating on the nameplate of the motor.

Hoist overload Reduce load to within rated capacity of hoist.

Motor overheated andthermal overloadprotector has tripped

See Trouble Shooting Problem "Motor or brake overheating".

Improper, loose, orbroken wire in hoistelectrical system

Shut off power supply, check wiring connections on hoistcontrol panel and inside push-button pendant.

Check motor brake adjustment for proper clearance.Brake does notrelease Check voltage and frequency of power supply against the

rating on the nameplate of the motor.

Faulty magneticcontactor

Check coil for open or short circuit. Check all connections inthe control circuit. Check for open contactors. Replace asneeded.

Defect in controltransformer

Check transformer coil for signs of overheating. Disconnecttransformer and check for open winding.

Hoist will not operate

Motor burned out Replace motor frame/stator, shaft/rotor, and any otherdamaged parts.

Down circuit open Check circuit for loose connections. Check down side of limitswitch for malfunction.

Broken conductor inpendant cord

Check the continuity for each conductor in the cable. If one isbroken, replace entire cable.

Faulty magneticcontactors

Check coils for open or short circuit. Check all connections onmotor circuit. Check for burned contacts. Replace as needed.

Hoist lifts but will notlower

Faulty switch inpendant

Check electrical continuity. Check electrical connections.Replace or repair as needed.

Appendix C67

Table 7-1 Troubleshooting Guide

Symptom Cause Remedy

Hoist overloaded Reduce load to within rated capacity of hoist.

Low voltage in hoist'spower supply

Determine cause of low voltage and bring to within plus orminus 10% of the voltage specified on the motor nameplate.The voltage should be measure at the hoist contactor.

Up circuit open Check circuit for loose connections. Check up side of limitswitch for malfunction.

Broken conductor inpendant cord

Check the continuity of each conductor in the cable. If one isbroken, replace entire cable.

Faulty magneticcontactor

Check coils for open or short circuit. Check all connections onmotor circuit. Check for burned contacts. Replace as needed.

Hoist lowers but willnot lift

Faulty switch inpendant

Check electrical continuity. Check electrical connections.Replace or repair as needed.

Faulty friction clutchRepair by a qualified person trained in the repair of hoists andproper friction clutch adjustment procedures. Replace asneeded.

Hoist overloaded Reduce load to within rated capacity.

Low voltage in hoist'spower supply

Determine cause of low voltage and bring to within plus orminus 10% of voltage specified on the motor nameplate. Thevoltage should be measured at the hoist contactor.

Brake drags Check motor brake adjustment for proper clearance.

Hoist will not lift ratedload or does not havethe proper liftingspeed

Faulty friction clutchRepair by a qualified person trained in the repair of hoists andproper friction clutch adjustment procedures. Replace asneeded.

Motor brake notholding

Clean and inspect brake lining. Check brake adjustment forproper clearance.Load drifts

excessively whenhoist is stopped

Mechanical Loadbrake not holding (ERonly)

Replace as needed. (ER only, NER has no load brake.)

Appendix C68

Table 7-1 Troubleshooting Guide

Symptom Cause Remedy

Excessive load Reduce load to within rated capacity of hoist.

Excessive duty cycle Reduce frequency of lifts.

Wrong voltage orfrequency

Check voltage and frequency of power supply against therating on the nameplate on the motor.

Brake drags Check brake adjustment for proper clearance.Motor or brakeoverheating

Extreme externalheating

Above an ambient temperature of 140°F, the frequency ofhoist operation must be reduced to avoid overheating of themotor. Special provisions should be made to ventilate thehoist or otherwise shield it from the heat.

Collectors makingpoor contact

Check movement of spring loaded arm, weak spring,connections, and shoe. Replace as needed.

Contactor contactsarcing Check for burned contacts. Replace as needed.

Loose connection incircuit

Check all wires and terminals for bad connections. Replaceas needed.

Hoist operatesintermittently

Broken conductor inPendant Cord

Check for intermittent continuity in each conductor thePendant Cord. Replace entire Pendant Cord if continuity isnot constant.

Appendix C69

� Single Speed Wiring diagram 1/8 Ton – 5 Ton Capacity

Consult factory for 8 – 20 Ton hoist wiring information.

Appendix C70

� Dual Speed Wiring Diagram 1/8 Ton – 5 Ton Capacity

Consult factory for 8 – 20 Ton hoist wiring information.

www.harringtonhoists.com

Harrington Hoists, Inc. Harrington Hoists – Western Division401 West End Avenue 2341 Pomona Rincon Rd. #103Manheim, PA 17545-1703 Corona, CA 92880-6973Phone: 717-665-2000 Phone: 909-279-7100Toll Free: 800-233-3010 Toll Free: 800-317-7111Fax: 717-665-2861 Fax: 909-279-7500

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